Method for Producing a Press-Hardened Molded Part, and Press-Hardening Tool

ABSTRACT

The invention relates to a method that is used to produce a press-hardened molded part ( 3 ) having at least two regions that differ regarding the strength of the regions by means of a press-hardening tool. A blank heated to a forming temperature is formed in the press-hardening tool and held in the press-hardening tool during the cooling for the purpose of heat-treating. In order to set the regions of lower strength, said regions are cooled more slowly than the other regions. During the forming step, the entire blank and thus also the regions of the blank intended to be set to a lower strength are in contact with a molding surface of the tool ( 1 ). After the conclusion of the forming step, the tool surface ( 2 ) in contact with the molded part is changed in such a way that the one or more regions to be set with lower strength have no tool contact during the cooling step that follows the forming step. According to the invention, the tool surface associated with the one or more regions of lower strength of the molded part ( 3 ) is formed by tool segments ( 5.1, 5.2, 5.3, 5.4 ) that can be adjusted relative to the remaining tool surface and the tool segments ( 5.1, 5.2, 5.3, 5.4 ) are adjusted after the forming step in order to change the tool surface ( 2 ), and the molding side of the one or more tool segments ( 5.1, 5.2, 5.3, 5.4 ) that forms the molding surface for the forming process is larger than the region of the molded part that is to be set with lower strength and that is associated with such a tool segment ( 5.1, 5.2, 5.3, 5.4 ). The invention further relates to a press-hardening tool having a shaping surface ( 2 ) for producing a press-hardened molded part ( 3 ) having at least two regions that differ regarding the strength of the regions. According to a first alternative, the tool surface associated with the regions of lower strength is formed by tool segments ( 5.1, 5.2, 5.3, 5.4 ) that can be adjusted relative to the remaining tool surface, and the molding surface of the one or more tool segments ( 5.1, 5.2, 5.3, 5.4 ) that forms the molding surface ( 6.1, 6.2, 6.3, 6.4 ) for the forming process is larger than the region of the molded part that is to be set with lower hardness due to strength by means of such a tool segment ( 5.1, 5.2, 5.3, 5.4 ).

The invention relates to a method for producing a press-hardened molded part having at least two regions that differ regarding their strength by means of a press-hardening tool in which a blank heated to a forming temperature is formed and held in the tool for the purpose of heat treating, wherein for adjusting the strength at least one region of lower strength this region is cooled more slowly compared to the regions that are to be adjusted with higher strength. The invention furthermore relates to a press-hardening tool with a forming surface for producing a press-hardened molded part having at least two regions that differ regarding their strength.

Press-hardening tools are tools for forming and hardening metal blanks. For the purposes of hardening, depending on the configuration of the method, an appropriately preheated blank is fed into the press-hardening tool in which it is formed and for its hardening is sufficiently quickly cooled and thus hardened after the forming has been completed. Such press-hardening tools for example are used for producing structural components of motor vehicles. The blanks are normally steel sheet blanks.

There are numerous applications in which a structural component for a motor vehicle with different mechanical properties is desired. Such structural component can be the B-pillar of a motor vehicle, for example. For a B-pillar, it is sometimes desired for the column to have less strength in the region of the base and thus increased ductility compared to the connecting regions of higher strength and a correspondingly lower ductility.

Such B-pillar is known from EP 1 180 470 B1, which for the purpose of adjusting the different strengths is differently heated in regions prior to introducing the blank. For this purpose, it is provided that those regions of the blank in which the formed molding must have regions of increased strength, these are heated to a higher temperature than those which must have lower mechanical strength properties in this regard. The method known from EP 1 180 470 B1 uses a steel blank in which the regions of higher strength in the molded part, i.e. the B-pillar, is heated to austenitizing temperature, while those regions of the blank in which the regions of the formed molded part must have lower strength are only heated to a temperature which is distinctly below the austenitizing temperature. In order to protect the regions that are to be heated to a lower temperature, EP 1 180 470 B1 proposes to insulate these regions. It has been shown however that this manner of handling the blanks is complicated. At the same time it must be recognized that a certain amount of lack of definition of the dimensional accuracy in the delimitation of the regions of higher strength has to be accepted.

WO 2006/038868 A1 discloses an additional method of how to produce press-hardened moldings with regions of different strength. In this known method, it is provided to configure the tool design such that those regions of the blank in which the formed molding must have a lower strength are located in a tool cavity. To be able to also hold the molded part in the tool in the regions where the strength is to be adjusted lower, support structures are incorporated into the cavity, which are supported on the molded part. The contact area between the molding surface of the tool and the molded part within such cavity amounts to less than 25% of the surface area. Even if it is possible to produce structural components having regions of different strength using the method described in this document and the press-hardening tool which is also described therein, wherein the blank was previously heated uniformly to its forming temperature, the dimensional accuracy of the molded parts produced with this method and/or with this tool is frequently not sufficient. Especially with such structural components in which seals are to be used, as is the case with a B-pillar, for example, the molded parts produced with this method do not meet the necessary tolerance requirements. In the methods which became known from the prior art, those regions of the molding are moreover limited with respect to their size which have a lower strength throughout, since regions of higher strengths are formed in the contact areas.

Based upon the discussed prior art, the object of the invention therefore is to develop a method named at the outset as well as a press-hardening tool named at the outset in such a manner that the advantages in handling of the method known from WO 2006/038868 A1 can be realized, wherein the dimensional accuracy of the molded parts produced with it is improved, nevertheless, the limitations regarding the size of the regions of lower strength do not have to be contended with and no losses in the surface quality have to be accepted.

The invention teaches that this object is solved by a method having the features of claim 1.

The invention teaches that this object is moreover solved by a press-hardening tool having the features described in claim 5 or 9.

In the previously described method, and the same applies also for the press-hardening tool described in claim 5, a press-hardening tool is used, the tool surface of which can be changed. The changeability of the tool surface of the tool, i.e. of the one surface that is abutted by the blank and/or by the formed molded part, relates to its contact area with the molded part. The changeability of the tool surface is provided in such a way that although a closed tool surface is provided for the forming step, on which the blank to be formed and/or the formed molding are abutting. For the purposes of adjusting the regions of different strengths, the tool surface is changed subsequently to the forming step, namely in such a manner that the effective tool surface for the forming step is retracted from the molded part surface on which the regions of the molding with the lower strength to be adjusted are abutting during the cooling step. Consequently, these molding surface regions do not or at least temporarily do not abut against the molding surface for the step of cooling. Since the tool is cooled, the cooling process takes place in those sections of the molded part, in which no tool surface abuts against the molding, distinctly slower than in the other tool regions. What is used with this concept is that for adjusting the regions with higher strength of the molded part, a specific cooling rate must be adhered to. This cannot be achieved in those regions in which no tool surface abuts against the molding surface during the cooling process, which is why these regions are not being hardened and thus only have lower mechanical strength properties. In the above-described concept it has thus been ensured that the cooling process can be selectively performed differently in the different molded part regions. In those regions, in which a lower strength is desired, the contact time of the molding with the one or more tool segments is reduced during the cooling process compared to the molded part regions in which a higher strength is to be adjusted. This does not mean that these molded part regions must not have any contact with the tool segment during the entire cooling process. What is decisive is that the tool segments assigned to the molded part regions of lower strength with reference to the molded part surface that abuts against it during the forming process are controlled such that the cooling rate is reduced compared to the other regions of the molded part. Apart from the option to leave the one or more tool segments in a retracted position from the regions of the molded part to be adjusted with lower strength during the entire cooling process, it is also possible to retract them intermittently against the regions of the molded part intermittently once or even multiple times. This makes it possible to influence the cooling rate. In addition, such a measure assists the dimensional accuracy of these molded part regions. In addition or even in place of the single or multiple retraction of the one or more tool segments against the molded part surface during the cooling process, the molded part regions with lower strength can also be calibrated in the described manner after the cooling process has been completed.

The molding surface of the mold side wall of the one or more tool segments abutting against the molded part for the forming process is larger than the region of the molded part to be adjusted by an adjustment of these tool segments with lower strength. In this embodiment, not only the actual region of the molded part is assigned against the side wall of the one or more tool segments which abuts therein during the forming process, but at least partially the connecting transition regions in those regions of the molded part with higher strength. This concept permits the press-hardening tool to be configured such that the tool segments can be adjacent to each other, leaving no gaps. This is essential to prevent tool imprints on the upper side of the molded part in the course of the forming process.

Since the blank abuts with its full surface against a tool surface during the forming step and this is maintained right up to the end or at least until shortly before the forming step is completed, this is the reason for the particular dimensional accuracy of molded parts produced with this method and also with such press-hardening tool.

The handling of such tool is uncomplicated and can also be controlled automatically. The tool surface regions onto which those regions of the blank and/or the molded part abut during the forming step, and in which a lower strength must be adjusted, are typically formed by tool segments that are moved like slides, for example. Such process can be performed fully automatically. It is particularly not required to heat a blank differently over regions before it is formed.

As a result of changing the effective tool surface between the forming step and the cooling step, this will not only ensure a particularly high dimensional accuracy in the final geometry of the molded part, but also acute and especially repeatable reciprocal delimitation of the regions of different strength, and process stability.

This method and the described press-hardening tool can be used particularly advantageously for the press-hardening of sheet steel blanks. In such case the blank is brought to its austenitizing temperature before it is fed to the press-hardening tool for the purposes of forming and its partial hardening.

A particular advantage with the method described and with the pressing tool described is also that one and the same structural component can be produced with regions of different strength or also without such regions. With tools, with which a change of the tool surface is possible in different regions of the tool surface, by activating or correspondingly not activating the tool segments referred to it is possible to produce molded parts in which either the total number of the possible regions have a lower strength, or only individual ones of same, or that the entire molded part is hardened uniformly. This permits using one and the same press-hardening tool for producing molded parts of the same geometry, on which different regions can have a lower hardness, however.

Pursuant to a further proposed solution of a press-hardening tool, it is provided that the tool surface assigned to the one or more regions of lower strength of the molded part is constructed of a material that has a lower thermal conductivity with respect to the material of the remaining tool surface, namely such that the cooling rate of the regions of the molded part abutting thereon is less than that required for hardening to produce the regions with higher strength.

Also with this press-hardening tool, the cooling of those regions of the molded part that are to be adjusted with a lower strength is slower than in the remaining regions in which the molded part must have a higher strength. With this proposed solution, this is done by the corresponding design of the one or more tools of the press-hardening tool, which are heat insulated in the respective regions and consequently have material properties comprising low thermal conductivity, which results in slowing down the cooling process and for this reason the necessary cooling rate to develop a region of higher strength cannot be achieved. These surfaces typically involve mold inserts made of a ceramic material, for example. Also with this pressing tool, the molding surfaces of the tools act with their full surface on the blank or the molded part, which ensures the high dimensional accuracy of the molded parts produced with this press-hardening tool. Further advantages and embodiments of the invention result from the subsequent description of embodiments, making reference to the enclosed figures, which show the following:

FIG. 1: illustrates a part of a press-hardening tool with its bottom die and an already formed molded part bearing on it, with the bottom die for providing a first tool surface,

FIG. 2: illustrates the bottom die of FIG. 1 in a second position for providing a tool surface which differs from the tool surface of the position of FIG. 1.

FIG. 3: illustrates the press-hardening tool of FIG. 1 with a further position of its bottom die for providing a different tool surface compared to the tool surface of the tool of FIG. 2,

FIG. 4: illustrates the press-hardening tool which is designed in principle as the one of FIG. 1, pursuant to a further embodiment, and

FIG. 5: illustrates a further bottom die of a press-hardening tool.

FIG. 1 shows the bottom die 1 of a press-hardening tool which is otherwise not illustrated in greater detail. On its molding surface 2 bears an already formed blank, a molded part 3, namely such as this has been arranged on the molding surface 2 following the forming process. In addition to the bottom die 1, also an upper die, which is not represented in the figures, is assigned to the press-hardening tool. The upper die is designed in the same manner as the bottom die 1 which is subsequently described in greater detail.

The bottom die 1 is composed of multiple tool components. These include a basic tool body 4. The tool body 4 is cooled in a manner which is not illustrated in greater detail. In addition to the basic tool body 4, the bottom die 1 has multiple tool segments 5.1, 5.2, 5.3 and 5.4, which are adjustable with respect to the basic tool body 4, namely in a manner so that their forming area on the tool segment 5.1, which is marked with the reference symbol 6.1, which is facing towards the molded part 3, can be retracted with respect to the molding surface 2 of the basic tool body 4. The tool segment 5.1 is located in the vicinity of the base of the molded part 3; the tool segments 5.2, 5.3 and 5.4 in the vicinity of a flange 7. The upper die that is not represented in the figures is partitioned accordingly, so that on the positions opposite the tool segments 5.1-5.4 of the molded part 3, such tool segments are also provided that can likewise be retracted and which are shaped complementary with respect to their molding surface.

FIG. 1 shows the molding surface 2 provided by the bottom die 1, said surface being used for forming a steel sheet blank that has been heated to its austenitizing temperature.

The described press-hardening tool with its bottom die 1 and its upper die (not shown) is used for producing a molded part, which, in the illustrated embodiment is a B-pillar with regions of different strength for a motor vehicle. The regions of different strength in the molded part 3 are adjusted in that the following is done after the forming step, i.e.: only after the bottom die 1 and the upper die have performed their press movement for forming the steel sheet blank, that those tool segments that are retracted from the surface of the molded part 3 in which a lower strength is to be adjusted in regions of the molded part abutting thereon during the forming step. It will be appreciated that the press-hardening tool with its bottom die 1 and its upper die is designed in such a manner that the tool segments are located at those positions in which regions of lower strength to be adjusted on the molded part abut.

FIG. 2 for example illustrates a position of the tool segments 5.2, 5.3 and 5.4 by means of which changed molding surface [sic] only in a part of the flange 7 of the molded part 3 a reduced strength is to be adjusted. Consequently, the tool segments 5.2, 5.3 and 5.4 with their molding surface 6.2, 6.3, 6.4 are retracted from the respective sections of the flange 7 forming the forming step and after changing the tools surface by retraction of the tool segments 5.2, 5.3 and 5.4 from the surface of the flange 7. This flange section 7 is therefore located within the still closed press-hardening tool in a cavity filled with air. This results in that the cooling rate of this section of the flange 7 because of the significantly lower thermal conductivity of air compared to the thermal conductivity of the tool steel of the basic tool body 4 and of the tool segment 5.1 likewise still abuts with its forming area 6.1 on the molded part 3. In the areas of the molded part 3 with which it bears upon the effective molding surface of the lower part of the tool, this will be cooled at a rate which is necessary for the desired hardening process. Therefore, in these areas of the molded part 3 a higher strength is adjusted by the cooling in the form of quenching than in those areas of the molded part 3 which do not have any contact with the tool during the cooling step, as is the case with the illustrated embodiment with respect to a part of the flange 7.

FIG. 3 illustrates the bottom die 1 of the press-hardening tool with another embodiment of its effective molding surface for adjustment and of areas of different strength. In contrast to the embodiment of the effective tool surface provided for the cooling step in the embodiment FIG. 2, the embodiment of FIG. 3 provides to retract the tool segments 5.1 and 5.2 from the surface of the molded part 3.1. Consequently, in an embodiment of the cooling surface of the bottom die 1, as illustrated in FIG. 3, in the area of the base of the B-pillar formed by the molded part 3.1, a region of lower strength is adjusted same as in a short section of the flange 7.1.

With the bottom part of the tool 1, the tool segments 5.1, 5.2, 5.3 and 5.4 are adjustable in the vertical direction relative to the basic tool body 4 as indicated by the arrows in FIGS. 2 and 3, in a manner which is not illustrated in greater detail

FIG. 4 shows a further bottom die 1.1 of a press-hardening tool which is otherwise not illustrated in greater detail. In principle, this is constructed like the bottom die 1 of FIGS. 1 to 3. The bottom die 1.1 differs from what is described above, in that only one tool segment 5.5 is arranged in the area of the flange 7. This can be adjusted in the horizontal direction for the retraction of its forming area 6.5 from the surface of the molded part 3 which bears on the bottom die 1.1.

FIG. 5 shows still a further bottom die 1.2 of a press-hardening tool which is otherwise not illustrated in greater detail. With this bottom die 1.2, it is provided to adjust regions of reduced strength in the area of a flange 7.1 to be developed, in order to carry out spot welding thereon. For this reason, the bottom die 1.2 has individual tool segments 5.6 on those positions, on which spot welds are to be performed on the molded part 3.2 to be produced. These are illustrated in FIG. 5 with their forming area retracted from the surface of the molded part 3.2.

Using tools of the type described above, molded parts can be produced in which the regions of higher strength comprise tensile strengths (R_(m)) of 1300 to 1950 MPa and yield points (R_(p0.2)) of 950 to 1520 MPa. The regions of reduced strength on the molded part can be realized, so that these comprise tensile strengths (R_(m)) from 550 to 750 MPa and a yield point (R_(p0.2)) of 350 to 600 MPa. It will be appreciated that these data are exemplary. These also depend on the material used for the blank. The exemplary data refer to a molded part made of steel sheet. The regions of lower strength that were adjusted on the molded part can be realized so that these comprise tensile strengths (R_(m)) of 550 to 750 MPa and a yield point of (R_(p0.2)) from 350 to 600 MPa. It will be appreciated that these data are exemplary. These also depend on the material used for the blank. These exemplary data refer to a molded part made of steel sheet. The difference in the mechanical strength properties makes it clear that the described method as well as the described press-hardening tools are suitable for adjusting regions of different strength with a high contrast in the strength.

According to an alternative embodiment of a press-hardening tool, those tool surface regions are provided with a thermal insulation insert, on which the form blank abuts with one surface region in which a lower strength is to be adjusted. Because such mold insert has a substantially lower thermal conductivity, the cooling rate with this press-hardening tool is decelerated. In this embodiment, adjustable tool segments are not required, in principle.

The sidewall of a tool segment or of a heat insulating material inserts is typically greater all-round than that region in which the lower strength is to be adjusted. This takes into account that a certain transition zone exists between the regions of higher strength and those of lower strength.

LIST OF REFERENCE SYMBOLS

-   1, 1.1, 1.2 Bottom die -   2 Molding surface -   3, 3.1, 3.2 Molded part -   4 Basic tool body -   5.1, 5.2, 5.3, 5.4, 5.5, 5.6 Tool segment -   6.1, 6.2, 6.3, 6.4 Molding area -   7, 7.1 Flange 

1. A method for producing a press-hardened molded part (3, 3.1, 3.2) comprising at least two regions that differ regarding the strength of the regions by using a press-hardening tool, in which a blank heated to a forming temperature is formed and is held in the press-hardening tool for the purpose of heat treating, wherein for adjusting the strength in the at least one region of lower strength this region is cooled more slowly compared to the regions to be adjusted with higher strength, characterized in that during the forming step, the entire blank and thus also the regions of the blank intended to be adjusted to a lower strength are in contact on a molding surface (2) of the tool (1, 1.1, 1.2) and after the conclusion of the forming step, the tool surface in contact with the molded parts (3, 3.1, 3.2) is changed in such a way that the one or more regions to be adjusted with lower strength have no tool contact during the cooling step that follows the forming step, wherein the tool surface assigned to the one or more regions of lower strength of the molded parts (3, 3.1, 3.2) is formed by tool segments (5.1, 5.2, 5.3, 5.4, 5.5, 5.6), can be adjusted relative to the remaining tool surface, and the tool segments (5.1, 5.2, 5.3, 5.4, 5.5, 5.6) for changing the tool surface (2) are adjusted after the forming step and wherein the sidewall which is developing the molding surface for the forming process of the one or more tool segments (5.1, 5.2, 5.3, 5.4, 5.5, 5.6) is larger than the region of the molded part to be adjusted with lower strength that is assigned to such tool segment (5.1, 5.2, 5.3, 5.4, 5.5, 5.6).
 2. The method according to claim 1, characterized in that the tool surface is changed in such a way that the one or more regions of the molded part (3, 3.1, 3.2) to be adjusted with lower strength are in a tool cavity during the cooling process.
 3. The method according to claim 1 or 2, characterized in that the blank has been heated to a uniform forming temperature before this blank which is at its forming temperature is subjected to the press-hardening process.
 4. The method according to any of the claims 1 to 3, characterized in that a steel sheet blank, for example a steel sheet plate, which is heated to an austenitizing temperature, is used as blank.
 5. The press-hardening tool with a formative surface (2) for producing a press-hardened molded part (3, 3.1, 3.2) comprising at least two regions that differ with regard to their strength, characterized in that the tool surface (6.1, 6.2, 6.3, 6.4, 6.5) assigned because of lower strength of the molded part is constituted by tool segments (5.1, 5.2, 5.3, 5.4, 5.6) that can be adjusted relative to the remaining tool surface and that the forming area (6.1, 6.2, 6.3, 6.4, 6.5) of the one or the more tool segments (5.1, 5.2, 5.3, 5.4, 5.5, 5.6) constituting the molding area for the forming process of the one or more tool segments (5.1, 5.2, 5.3, 5.4, 5.5, 5.6) is larger than the region of lower hardness that can be respectively adjusted by the strength of the molded part.
 6. The press-hardening tool according to claim 5, characterized in that the molding area (6.1, 6.2, 6.3, 6.4, 6.5) of the one or more tool segments (5.1, 5.2, 5.3, 5.4, 5.5, 5.6) is larger on all sides than the region of the molded part (3, 3.1, 3.2) which is to be adjusted with lower strength which is in contact with it at the completion of the forming step.
 7. The press-hardening tool according to claim 5 or 6, characterized in that the one or more tool segments (5.1, 5.2, 5.3, 5.4, 5.5, 5.6) of the press-hardening tool (1, 1.1, 1.2) can be respectively adjusted inside the tool like a slider.
 8. The press-hardening tool according to any of the claims 5 to 7, characterized in that the mold halves of the press-hardening tools that are interacting with each other comprise adjacent adjustable tool segments at opposite positions with reference to a molded part therein.
 9. The press-hardening tool with a formative surface for producing a press-hardened molded part comprising at least two regions that differ regarding their strength, characterized in that the tool surface assigned to the one or the more regions of lower strength of the molded part is constructed of a material that has a lower thermal conductivity relative to the material of the remaining tool surface, namely such that the cooling rate of the regions of the molded part abutting thereon is smaller than that required for hardening to produce the regions with higher strength.
 10. The press-hardening tool according to claim 9, characterized in that the tool surface assigned to the one or the more regions of lower strength of the molded parts is constructed by one or more multiple mold inserts.
 11. The press-hardening tool according to claim 10, characterized in that the mold inserts are manufactured from a ceramic material.
 12. The press-hardening tool according to any of the claims 9 to 11, characterized in that the tool surface assigned to the one or the more regions of lower strength of the molded part is constructed by tool segments that can be adjusted relative to the remaining tool surface.
 13. The press-hardening tool according to claim 12, characterized in that this comprises one or multiple additional features according to any of the claims 5 to
 8. 